Teledyne 3190 User Manual

OPERATING INSTRUCTIONS

FOR

Model 3190 Series

Trace Oxygen Analyzer

DANGER

HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM.

PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.

HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A
TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.

ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/MANAGER.

Teledyne Analytical Instruments

P/N M64641

06/21/2000

ECO # 00-0221

i

Copyright © 1999 Teledyne Analytical Instruments

All Rights Reserved. No part of this manual may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any other language or computer
language in whole or in part, in any form or by any means, whether it be electronic,
mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of
Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-

1580.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us
free from defects of material and of construction, and that our liability shall be limited to
replacing or repairing at our factory (without charge, except for transportation), or at
customer plant at our option, any material or construction in which defects become
apparent within one year from the date of shipment, except in cases where quotations or
acknowledgements provide for a shorter period. Components manufactured by others bear
the warranty of their manufacturer. This warranty does not cover defects caused by wear,
accident, misuse, neglect or repairs other than those performed by Teledyne or an autho­rized service center. We assume no liability for direct or indirect damages of any kind and
the purchaser by the acceptance of the equipment will assume all liability for any damage
which may result from its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our
apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in
so far as such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by
which valuable data can be gathered. The information provided by the instrument may
assist the user in eliminating potential hazards caused by his process; however, it is
essential that all personnel involved in the use of the instrument or its interface, with the
process being measured, be properly trained in the process itself, as well as all instrumen­tation related to it.

The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent
danger, it has no control over process conditions, and it can be misused. In particular, any
alarm or control systems installed must be tested and understood, both as to how they
operate and as to how they can be defeated. Any safeguards required such as locks, labels,
or redundancy, must be provided by the user or specifically requested of Teledyne at the
time the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions. The
purchaser is responsible for the training of personnel, for providing hazard warning
methods and instrumentation per the appropriate standards, and for ensuring that hazard
warning devices and instrumentation are maintained and operated properly.

Teledyne Analytical Instruments (TAI), the manufacturer of this instrument,
cannot accept responsibility for conditions beyond its knowledge and control. No
statement expressed or implied by this document or any information disseminated by the
manufacturer or its agents, is to be construed as a warranty of adequate safety control

under the user’s process conditions.

ii Teledyne Analytical Instruments

Specific Model Information

The instrument for which this manual was supplied may incorporate one or
more options not supplied in the standard instrument. Commonly available
options are listed below, with check boxes. Any that are incorporated in the
instrument for which this manual is supplied are indicated by a check mark in the
box.

Instrument Serial Number: _______________________

Options Included in the Instrument with the Above Serial Number:

❑❑

❑ Class A-2C Micro-Fuel Cell: For 0-100% CO

❑❑

Purpose (range 0-10 ppm O2 minimum).

❑❑

❑ Class B-2C Micro-Fuel Cell: For General Purpose and high hydrogen

❑❑

or helium backgrounds (range 0-10 ppm
O2 minimum).

background and General

2

❑❑

❑ Class Z-2C Micro-Fuel Cell: For faster recovery after air calibration

❑❑

(range 0-200 ppm O2 minimum).

Class B-2C is the standard cell provided.

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Contents

Introduction

1.1 Overview ........................................................................ 1-1

1.2 Main Features of the Analyzer ....................................... 1-1

1.3 Front Panel Description.................................................. 1-2

1.4 Rear Panel Description .................................................. 1-3

Operational Theory

2.1 Introduction .................................................................... 2-1

2.2 Micro-Fuel Cell Sensor .................................................. 2-1

2.2.1 Principles of Operation .......................................... 2-1

2.2.2 Anatomy of a Micro-Fuel Cell................................. 2-2

2.2.3 Electrochemical Reactions .................................... 2-3

2.2.4 The Effect of Pressure............................................ 2-4

2.2.5 Calibration Characteristics ..................................... 2-4

2.3 Electronics ..................................................................... 2-5

2.3.1 General .................................................................. 2-5

2.3.2 Signal Processing .................................................. 2-5

Installation

3.1 Unpacking the Analyzer ................................................. 3-1

3.2 Location and Mounting .................................................. 3-2

3.2.1 Control Unit Installation.......................................... 3-2

3.2.2 External Probe Installation ..................................... 3-2

3.2.3 Installing the Micro-Fuel Cell ................................. 3-3

3.3 Electrical Connections ................................................... 3-3

3.4 Gas Connections ........................................................... 3-7

3.5 Installation Checklist ...................................................... 3-7

Operation

4.1 Introduction .................................................................... 4-1

4.2 Using the Function and Data Entry Buttons ................... 4-2

4.3 Setting the Analysis Ranges .......................................... 4-2

4.3.1 HI Range ............................................................... 4-3

4.3.2 LO Range .............................................................. 4-3

4.3.3Settle Mode ............................................................... 4-3

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4.4 Setting the Alarm Setpoints............................................ 4-3

4.4.1 HI Alarm ................................................................. 4-3

4.4.2 LO Alarm ................................................................ 4-3

4.4.3 Sensor Fail Alarm .................................................. 4-4

4.5 Selecting a Fixed Range or Autoranging ....................... 4-4

4.6 Calibration ..................................................................... 4-4

4.7 Displaying Percent & PPM on the LED Display ............. 4-5

4.8 "SetL" mode in the LED display ..................................... 4-6

Maintenance

5.1 Replacing the Fuse ........................................................ 5-1

5.1.1 AC Powered Units ................................................. 5-1

5.1.2 DC Powered Units ................................................. 5-2

5.2 Sensor Installation or Replacement ............................... 5-2

5.2.1 When to Replace a Sensor .................................... 5-2

5.2.2 Ordering and Handling of Spare Sensors .............. 5-3

5.2.3 Removing the Micro-Fuel Cell ............................... 5-3

5.2.4 Installing a Micro-Fuel Cell .................................... 5-4

5.2.5 Cell Warranty Conditions ....................................... 5-5

Appendix

A.1 Specifications ................................................................ A-1

A.2 Spare Parts List ............................................................. A-2

A.3 Drawing List ................................................................... A-3

A.4 Miscellaneous ................................................................ A-3

A.5 Material Safety Data Sheet ............................................ A-4

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vi Teledyne Analytical Instruments

Trace Oxygen Analyzer Introduction 1

Introduction

1.1 Overview

The Teledyne Analytical Instruments (TAI) Model 3190 is a micropro­cessor-based trace oxygen analyzer for real-time measurement of trace
amounts of oxygen in inert gases, or in a wide variety of gas mixtures. It
features simple operation, fast response, and a compact, rugged construction.
Typical applications of the Model 3190 are monitoring nitrogen generators
and inert gas blanketing applications.

1.2 Main Features of the Analyzer

The main features of the analyzer include:

• High resolution, accurate readings of oxygen content from
0-10 ppm through 0-25 %. Large, bright, light-emitting-diode
meter readout.

• Simple pushbutton controls.

• Nylon cell holder.

• Advanced Micro-Fuel Cell, for trace analysis, has a six (6)

months warranty and expected lifetime.

• Unaffected by oxidizable gases.

• Fast response and recovery time.

• Microprocessor based electronics: 8-bit CMOS microprocessor

with on-board RAM and 16 kB ROM.

• Two user selectable ranges (from 0-10 ppm through
0-9,999 ppm) allow best match to users process and equipment.

• Air-calibration range for convenient spanning at 20.9 %.

• Operator can select Autoranging, which allows the analyzer to

automatically select the proper preset range for a given
measurement, or he can lock the analyzer onto a single range.

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1 Introduction Model 3190

• Two concentration alarms with adjustable setpoints.

• Sensor failure alarm.

• RS-232 serial digital port for output of concentration and range

data to a computer, terminal, or other digital device.

• Three analog outputs: two for measurement (0–10 V dc, and
negative ground 4–20 mA dc) and one for range identification
(0-10 V dc).

• Compact and rugged Control Unit with flush-panel case.
Designed for indoor use. Front panel NEMA-4 rated.

• External Probe can be located six feet or more away, depending
on the existing electromagnetic noise level.

1.3 Front Panel Description

All controls and displays except the power switch are accessible from
the front panel. See Figure 1-1. The front panel has seven pushbutton mem­brane switches, a digital meter, and an alarm indicator LED for operating the
analyzer. These features are described briefly here and in greater detail in
Chapter 4, Operation.

Figure 1-1: Front Panel

Function Keys: Seven pushbutton membrane switches are used to
select the function performed by the analyzer:

1-2

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Trace Oxygen Analyzer Introduction 1

• Set HI Alarm Set the concentration ABOVE which an

alarm activates.

• Set LO Alarm Set the concentration BELOW which an

alarm activates.

• Set HI Range Set the high analysis range for the instrument

(up to 0-9999 ppm).

• Set LO Range Set the low analysis range for the instrument

(down to 0-10 ppm).

• Span Span calibrate the analyzer.

Data Entry Keys: Two pushbutton membrane switches are used to

manually change measurement parameters of the instrument as they are
displayed on the LED meter readout:

• Up Arrow Increment values of parameters upwards as

they are displayed on the LED readout.

• Down Arrow Increment values of parameters downwards as

they are displayed on the LED readout.

Digital LED Readout: The digital display is a LED device that

produces large, bright, 7-segment numbers that are legible in any lighting
environment. It has two functions:

• Meter Readout: As the meter readout, it displays the oxygen

concentration currently being measured.

• Measurement Parameters Readout: It also displays user-

definable alarm setpoints, ranges, and span calibration point
when they are being checked or changed.

1.4 Rear Panel Description

The rear panel contains the electrical input and output connectors.
Separate rear panel illustrations are shown in Figure 1-2 for the AC and DC
powered versions of the instrument. The connectors are described briefly
here and in detail in the Installation chapter of this manual.

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1 Introduction Model 3190

1-4

Figure 1-2 Rear Panel (AC and DC versions)

• Power Connection AC version: 100–240 V ac, at 50/60 Hz.

The connector housing includes the fuse
holder and the power switch.
DC version: Requires between 10 and
36 V dc.

Fuse Holder: Replacing the fuse is
described in Chapter 5, Maintenance.

I/O Power Switch: Turns the instrument
power ON (1) or OFF (0).

• Analog Outputs 0–10 V dc concentration output.
0–10 V dc range ID (or optional

overrange) output.
4–20 mA dc concentration output,
negative ground.

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Trace Oxygen Analyzer Introduction 1

• Alarm Connections HI Alarm, LO Alarm, and Sensor Failure

Alarm connections.

• RS-232 Port Serial digital output of concentration and

range signals.

• External Probe Connects to the Remote Probe or remote

Analysis Unit.

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1 Introduction Model 3190

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Trace Oxygen Analyzer Operational Theory 2

Operational Theory

2.1 Introduction

The analyzer is composed of two subsystems:

1. Analysis Unit with Micro-Fuel Cell Sensor

2. Control Unit with Signal Processing, Display and Controls

The Analysis Unit is designed to accept the sample gas and direct it to
the sensitive surface of the Micro-Fuel Cell sensor. The Micro-Fuel Cell is
an electrochemical galvanic device that translates the amount of oxygen
present in the sample into an electrical current.

The Control Unit processes the sensor output and translates it into
electrical concentration, range, and alarm outputs, and a trace oxygen
meter readout. It contains a microcontroller that manages all signal pro­cessing, input/output, and display functions for the analyzer.

2.2 Micro-Fuel Cell Sensor

2.2.1 Principles of Operation

The oxygen sensor used in the Model 3190 is a Micro-Fuel Cell
designed and manufactured by TAI. It is a sealed, disposable electrochemi­cal transducer.

The active components of the Micro-Fuel Cell are a cathode, an
anode, and the 15 % aqueous KOH electrolyte in which they are immersed.
The cell converts the energy from a chemical reaction into an electrical
current through an external electrical circuit. Its action is similar to that of
a battery.

There is, however, an important difference in the operation of a
battery as compared to the Micro-Fuel Cell: In the battery, all reactants are

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2 Operational Theory Model 3190

stored within the cell, whereas in the Micro-Fuel Cell, one of the reactants
(oxygen) comes from outside the device as a constituent of the sample gas
being analyzed. The Micro-Fuel Cell is therefore a hybrid between a
battery and a true fuel cell. (All of the reactants are stored externally in a
true fuel cell.)

2.2.2 Anatomy of a Micro-Fuel Cell

The Micro-Fuel Cell is a cylinder only 1¼ inches in diameter and 1
inch thick. It is made of extremely inert plastic, which can be placed
confidently in practically any environment or sample stream. It is effec­tively sealed, although one end is permeable to oxygen in the sample gas.
The other end of the cell is a contact plate consisting of two concentric foil
rings. The rings mate with spring-loaded contacts in the sensor block
assembly and provide the electrical connection to the rest of the analyzer.
Figure 2-1 illustrates the external features.

Figure 2-1: Micro-Fuel Cell

Refer to Figure 2-2, Cross Section of a Micro-Fuel Cell, which illus-
trates the following internal description.

2-2

Figure 2-2. Cross Section of a Micro-Fuel Cell (simplified)

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Trace Oxygen Analyzer Operational Theory 2

At the top end of the cell is a diffusion membrane of Teflon, whose
thickness is very accurately controlled. Beneath the diffusion membrane
lies the oxygen sensing element—the cathode—with a surface area almost
4 cm2. The cathode has many perforations to ensure sufficient wetting of
the upper surface with electrolyte, and it is plated with an inert metal.

The anode structure is below the cathode. It is made of lead and has a
proprietary design which is meant to maximize the amount of metal avail­able for chemical reaction.

At the rear of the cell, just below the anode structure, is a flexible
membrane designed to accommodate the internal volume changes that
occur throughout the life of the cell. This flexibility assures that the sens­ing membrane remains in its proper position, keeping the electrical output
constant.

The entire space between the diffusion membrane, above the cathode,
and the flexible rear membrane, beneath the anode, is filled with electro­lyte. Cathode and anode are submerged in this common pool. They each
have a conductor connecting them to one of the external contact rings on
the contact plate, which is on the bottom of the cell.

2.2.3 Electrochemical Reactions

The sample gas diffuses through the Teflon membrane. Any oxygen
in the sample gas is reduced on the surface of the cathode by the following
HALF REACTION:

O2 + 2H2O + 4e

––

–

––

→ 4OH

––

–

––

(cathode)

(Four electrons combine with one oxygen molecule—in the presence
of water from the electrolyte—to produce four hydroxyl ions.)

When the oxygen is reduced at the cathode, lead is simultaneously
oxidized at the anode by the following HALF REACTION:

2Pb + 4OH

––

–

––

→ 2Pb+2 + 2H2O + 4e

––

–

––

(anode)

(Two electrons are transferred for each atom of lead that is oxidized.
TWO ANODE REACTIONS balance one cathode reaction to transfer four
electrons.)

The electrons released at the surface of the anode flow to the cathode
surface when an external electrical path is provided. The current is propor­tional to the amount of oxygen reaching the cathode. It is measured and
used to determine the oxygen concentration in the gas mixture.

The overall reaction for the fuel cell is the SUM of the half reactions
above, or:

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2 Operational Theory Model 3190

2Pb + O2 → 2PbO

(These reactions will hold as long as no gaseous components capable
of oxidizing lead—such as iodine, bromine, chlorine and fluorine—are
present in the sample. The only likely components are the halogens.)

The output of the fuel cell is limited by (1) the amount of oxygen in
the cell at the time and (2) the amount of stored anode material. In the
absence of oxygen, no current is generated.

2.2.4 The Effect of Pressure

In order to state the amount of oxygen present in the sample as a
specific portion of the gas mixture, it is necessary that the sample diffuse
into the cell under constant pressure.

If the total pressure increases, the rate that oxygen reaches the cathode
through the diffusing membrane will also increase. The electron transfer,
and therefore the external current, will increase, even though the oxygen
concentration of the sample has not changed. It is therefore important that
the sample pressure at the fuel cell (Usually vent pressure) remain rela­tively constant between calibrations.

2.2.5 Calibration Characteristics

Given that the total pressure of the sample gas on the surface of the
Micro-Fuel Cell input is constant, a convenient characteristic of the cell is
that the current produced in an external circuit of constant impedance is
directly proportional to the rate at which oxygen molecules reach the
cathode, and this rate is directly proportional to the concentration of oxy­gen in the gaseous mixture. In other words it has a linear characteristic
curve, as shown in Figure 2-2. Measuring circuits do not have to compen­sate for nonlinearities.

Also, since there is zero output in the absence oxygen, the characteris­tic curve has an absolute zero. The cell itself does not need to be zeroed.

As the cell reaches the end of its useful life, the slope seen in Figure
2-2 decreases. In the Model 3190, the slope is monitored. If the inverse of
the slope:

Span Value (ppm) / Cell Output (nA)

is over 4.447 ppm/nA, a sensor failure alarm is triggered, indicating that
the cell should be replaced.

2-4

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Trace Oxygen Analyzer Operational Theory 2

Figure 2-2. Characteristic Input/Output Curve for a Micro-Fuel Cell

2.3 Electronics

2.3.1 General

The signal processing uses an Intel microcontroller with on-board

RAM and ROM to control all signal processing, input/output, and display
functions for the analyzer. System power is supplied from a universal
power supply module designed to be compatible with most international
power sources.

The power supply circuitry is on the Power Supply PCB, which is

mounted vertically, just behind the rear panel of the Control Unit.

The signal processing electronics including the temperature compen­sated amplifier, microcontroller, analog to digital, and digital to analog
converters are located on the Main PCB, which is mounted vertically, just
behind the front panel of the Control Unit.

2.3.2 Signal Processing

Figure 2-3 is a block diagram of the signal processing electronics
described below.

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2 Operational Theory Model 3190

Figure 2-3: Block Diagram of the Signal Processing Electronics

In the presence of oxygen the cell generates a current. A current to

voltage amplifier (I–E AMPL) converts this current to a voltage.

The second stage amplifier (TEMP COMP) supplies temperature
compensation for the oxygen sensor output. The temperature compensation
amplifier incorporates a thermistor (THERM) that is physically located in
the cell block. The thermistor is a temperature dependent resistance that
changes the gain of the amplifier in proportion to the temperature changes
in the block. This change is inversely proportional to the change in the cell
output due to the temperature changes. As a result there is negligible net
change in the signal due to temperature changes once the sensor comes to
equilibrium. See Specifications in the Appendix.

The output from the temperature compensation amplifier is sent to an
analog to digital converter (ADC), and the resulting digital concentration
signal is sent to the microcontroller.

The digital concentration signal along with input from the front panel
buttons (KEYBOARD) is processed by the microcontroller, and appropri­ate output signals are directed to the display, alarm relays, and RS-232
output. The same digital information is also sent to a 12-bit digital to
analog converter (DAC) that produces the 0-10 V dc analog concentration
signal and the 0-10 V dc analog range ID output. A current to voltage
converter (E–I CONV) produces the 4-20 mA dc concentration signal.

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Trace Oxygen Analyzer Installation 3

Installation

Overvoltage
Category II

Installation of the analyzer includes:

1. Unpacking the system.

2. Mounting the Control Unit, External Sample Block, and Micro­Fuel Cell sensor.

3. Making the electrical connections.

5. Making the gas connections.

6. Testing the installation.

CAUTIONS: Read this chapter in its entirety before installing

the units.
The Model 3190 is for or indoor use only.
The sample must be free of entrained solids or

water. However, a high humidity sample is ideal,
since it will prevent water loss from the cell
electrolyte.

The Micro-Fuel Cell sensor electrolyte is caustic.
Do not attempt to open it. Leaking or exhausted
cells should be disposed of in accordance with
local regulations. Refer to the

Sheet

in the Appendix.

Material Safety Data

Any damage or scarring of the delicate permeable
membrane on the sensing end of the cell will
require cell replacement. Prevent contact with
membrane by any solid object.

3.1 Unpacking the Analyzer

As soon as you receive the instrument, carefully unpack and inspect
Control Unit, External Probe, and any included accessories for damage.
Immediately report any damage to the shipping agent. The analyzer is

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3 Installation Model 3190

shipped with all the materials you need to install and prepare the system for
operation.

CAUTION: Do not disturb the integrity of the cell package until

the cell is to be used immediately. If the cell package
is punctured prematurely and air is permitted to
enter, cell life will be shortened.

3.2 Location and Mounting

3.2.1 Control Unit Installation

The 3190 Control Unit is designed to be panel-mounted in a general
purpose, indoor area, away from moisture and the elements. The unit should
be installed at viewing level in a sheltered area.

CAUTION: For the DC powered version, the control unit

chassis must be isolated from the input power
ground.

Refer to the Outline Diagram C-64772 for the physical dimensions of
the analyzer.

3.2.2 External Probe Installation

The External Probe can be installed in the process any reasonable
distance from the Control Unit. The nominal maximum is 6 ft, but the dis­tance can be more, depending on the level of electromagnetic noise in the
operating environment.

The standard Model 3190 includes the External Probe unit depicted in
the Final Assembly, Dwg C-64641, and the Analysis Unit (probe) Outline,
Dwg B-59610. Dimensions are also given in Specifications in the Appendix.

For special applications, the type of External Probe unit supplied may
vary depending on the specific process. With these systems, specific installa­tion and interconnect information is given in a separate probe manual or in
an addendum to this manual depending on the model External Probe used.
The addendum will reference the specific Outline and Interconnection
Drawings in the Drawings section of this manual, and provides any other
appropriate information.

3-2

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Trace Oxygen Analyzer Installation 3

For special applications the Micro-Fuel Cell may also be of a different
type than the standard A-2C, B-2C or Z-2C unit. If this is the case, the
pertinent cell specifications will be given in the addendum.

3.2.3 Installing the Micro-Fuel Cell / Cell Block Orientation

A Micro-Fuel Cell is included as a separate item. It must be installed
prior to instrument use.

Also, once it is expended, or if the instrument has been idle for a
lengthy period, the Micro-Fuel Cell will need to be replaced.

Important Installation Note!

During the Installation and/or Replacement of the MFC, Membrane
surface MUST ALLWAYS FACE DOWNWARD, and the Contact side of
the Membrane, MUST be placed FIRST into Analysis Unit.

The reason for proper Installation/Replacement is, if any bubble that
develops as the electrolyte dries out will be directed by the gravity away
from the membrane.

To install or replace the Micro-Fuel Cell, follow the procedures in
Chapter 5, Maintenance.

3.3 Electrical Connections

Figure 3-1 shows the two alternate Model 3190 rear panels. The first
illustration shows the AC powered version, and the second illustration shows
the DC powered version. The difference between them is the power connec­tions. Both versions have identical connections for the External Probe, the
alarms, and for the digital and analog concentration outputs. For detailed
pinouts, see the wiring/interconnection drawings in the Drawings section at
the rear of this manual.

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3 Installation Model 3190

Figure 3-1 Rear Panel Electrical Connectors for AC and DC Units

Primary Input Power (AC version): The power cord receptacle, fuse

block and Power switch are located in the same assembly. A 6-foot, standard
AC power cord is supplied with the Control Unit. Insert the female plug end
of the power cord into the power cord receptacle.

The universal power supply allows direct connection to any 100-240 V ac,

50/60 Hz power source. The fuse block, to the right of the power cord
receptacle, accepts a 5 × 20 mm, 0.5 A, time-lag (T) fuse. (See Fuse Re-
placement in chapter 5, Maintenance.)

The Power switch is located on the right-hand end of the power source

input receptacle assembly.

Primary Input Power (DC version): The 10–36 V dc power is

connected via the + and − terminals in the upper left corner of the panel. The

3-4

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Trace Oxygen Analyzer Installation 3

fuse receptacle, to the right of the power terminal strip, holds a 0.5 A, very
quick acting fuse. (See Fuse Replacement in chapter 5, Maintenance.)

The Power switch is located below the fuse receptacle.

WARNING: INSERT THE STRIPPED TIPS OF WIRES ENTIRELY

INTO THE TERMINAL BLOCKS. DO NOT LEAVE
EXPOSED WIRE OUTSIDE OF THE HOLES IN THE
BLOCKS.

CAUTION: The control unit chassis must be isolated from the

grounding system of the DC input power.

Analog Outputs: There are three DC output signal connectors with
screw terminals on the panel. There are two wires per output with the polar­ity noted. See Figure 3-3. The outputs are:

0–10 V concentration: Voltage rises with increasing oxygen concentra-

tion, from 0 V at 0 oxygen content to 10 V at full
scale oxygen content. (Full scale = 100 % of
programmed range.)

0–10 V Range ID: 03.33 V = Low Range, 06.66 V = High Range,

10 V = Air Cal Range.

4–20 mA concentration: Current increases with increasing oxygen concen-

tration, from 4 mA at 0 oxygen content to 20 mA
at full scale oxygen content. (Full scale = 100 %
of programmed range.)

Alarm Relays: The three alarm-circuit connectors are screw terminals
for making connections to internal alarm relay contacts. There is one set of
contacts for each type of alarm. Contacts are Form C, with normally open
and normally closed contact connections capable of switching up to 0.5
ampere at 125 V ac into a resistive load.

The alarm relay circuits are designed for failsafe operation, meaning the
relays are energized during normal operation. If power fails the relays de­energize (alarms activated).

The contact connections are indicated diagrammatically on the rear
panel as Normally Closed, Common, and Normally Open. Figure 3-2
explains how these act in failsafe operation.

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3 Installation Model 3190

Figure 3-2: Contact ID for FAILSAFE Relay Operation

The specific descriptions for each type of alarm are as follows:

HI Alarm Configured as high alarm (actuates when concentration is

above threshold). Can be set anywhere within the full
range of the analyzer (0-9,999 ppm), but must be set
ABOVE the threshold set for the LO Alarm.

LO Alarm Configured as low alarm (actuates when concentration is

below threshold). Can be set anywhere within the full
range of the analyzer (0-9,999 ppm), but must be set
BELOW the threshold set for the HI Alarm.

Sensor Fail Actuates when the output of the Micro-Fuel Cell sensor

falls below the acceptable level.

RS-232 Port: The digital signal output is a standard RS-232 serial

communications port used to connect the analyzer to a modem or other
digital device. Only the output mode is implemented in this instrument. The
data is oxygen concentration and range information in serial digital form.

The RS-232 protocol allows some flexibility in implementation in the
choice of values for certain parameters. Table 3-1 lists the RS-232 values
required by the 3190 implementation.

Table 3-1: Required RS-232 Options

Parameter Setting

Baud 2400

Byte 8 bits

Parity none

Stop Bits 1

Message Rate 2 per second

External Probe: The receptacle for the analysis unit cable is located in
the lower left-hand corner of the rear panel. The 6-pin Mini-Fit™ connector

3-6

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Trace Oxygen Analyzer Installation 3

is keyed to fit only one way into the receptacle. Do not force it in. The other
end of the cable is made of four separate wires. These should be connected
to the terminal strip on the analysis unit as follows:

Red: #1
Black: #2
Green: #3
White: #4 interchanged, but be consistent.

Refer to the Final Assembly, Dwg. C-64641.

The green and white connectors can be

}

3.4 Gas Connections

Gas connection instructions depend on the specific External Probe used

and any special requirements of the process being monitored.

The standard Model 3190 External Probe has inlet and outlet fixtures
only. Calibration gasses must be tee'd into the sample inlet through appropri­ate valves. ¼ inch tube fittings are used. For metric installations, ¼ inch to 6
mm adapters are supplied.

In general, sample flow and pressure must not create significant
backpressure past the sensor. For the standard probe, 2 scfh is the nominal
recommended flowrate.

The pressure required will depend on the sampling system. When
venting into a constant pressure, such as the atmosphere, controlling input
pressure is simple. If you are venting into a system of varying pressure, then
some form of pressure regulation is required.

3.5 Installation Checklist

Before connecting the instrument to the power source and turning it on,
make sure you have:

• Correctly installed the Sample and Exhaust gas lines

• Opened the isolation valves

• Checked for leaks

• Set the sample pressure to 5–10 psig, nominal

Once the above checks have been made, you can connect to the power
source. The instrument is now ready for operation.

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3 Installation Model 3190

3-8

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Trace Oxygen Analyzer Operation 4

Operation

4.1 Introduction

Once the analyzer has been mounted, the gas lines connected and the
electrical connections made, the Analyzer can be configured for your appli­cation. This involves setting the system parameters:

• Defining the user selectable analysis ranges.

• Setting alarm setpoints.

• Calibrating the instrument.

All of these functions are performed via the front panel controls, shown
in Figure 4-1.

Analyzing for the trace oxygen level in the gas passing through the cell
block is the default mode of operation. As long as no front panel buttons are
being pressed the Analyzer is analyzing.

Figure 4-1: Front Panel Controls and Indicators

4.2 Using the Function and Data Entry

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4 Operation Model 3190

Buttons

When no buttons on the Analyzer are being pressed, the instrument is in
the Analyze mode. It is monitoring the amount of oxygen in the sample gas
that is flowing through the Remote Probe.

When one of the Function Buttons is being pressed, the Analyzer is in
the Setup mode or the Calibration mode.

The 4 Setup Mode buttons on the analyzer are:

• SET HI ALARM

• SET LO ALARM

• SET HI RANGE

• SET LO RANGE

The Calibration Mode button is:

• SPAN

The Data Entry buttons (∆ and ∇) increment the values displayed on
the TRACE OXYGEN meter while one of the Function buttons is being
held down.

• ∆ : Increments the displayed value upwards.

• ∇ : Increments the displayed value downwards.

Any of the functions can be selected at any time by holding down the
appropriate button.

Each function will be described in the following sections. Although the
operator can use any function at any time, the order chosen in this manual is
appropriate for an initial setup.

4.3 Setting the Analysis Ranges

The two user definable analysis ranges are both capable of being
adjusted for from 0-10 ppm to 0-9,999 ppm oxygen concentration.

Whatever values are selected, the analyzer automatically switches from
the LO range to the HI range when the oxygen concentration reaches the LO
range fullscale value, and it switches back to the LO range when the oxygen
concentration falls below the LO range fullscale value

Note: For proper operation, the HI Range setpoint should be set at a

higher concentration than the LO Range setpoint.

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Trace Oxygen Analyzer Operation 4

4.3.1 HI Range

Setting the HI Range fullscale value defines the LEAST sensitive

analysis range to be used. To set the HI Range:

1. Press the SET HI RANGE Function button once.

2. Immediately (within 5 seconds) press either the ∆ or ∇ button to

raise or lower the displayed value, as required, until the display
reads the desired fullscale concentration.

4.3.2 LO Range

Setting the LO Range fullscale value defines the MOST sensitive range

to be used. To set the LO Range:

1. Press the SET LO RANGE Function button once.

2. Immediately (within 5 seconds) press either the ∆ or ∇ button to

raise or lower the displayed value, as required, until the display
reads the desired fullscale concentration.

4.3.3 Settle Mode

The Model 3190 has two programmable ranges as discussed previous.
Occasionally, to maximize accuracy the microprocessor must make certain
adjustments to the gain of the amplifier which converts the sensor current
into a voltage. When these adjustments are being made, the outputs of the
analyzer are frozen and the LED will flash “SetL”. This condition will
persist for approximately 35 seconds and then normal operation will resume.

4.4 Setting the Alarm Setpoints

The alarm setpoints can be adjusted over the full range of the analyzer
(0-9,999 ppm oxygen content). The setpoint values are expressed in ppm
only.

Note: For proper operation, the HI Alarm setpoint should be set at a

higher concentration than the LO Alarm setpoint.

4.4.1 HI Alarm

Setting the HI Alarm sets the value ABOVE which the HI Alarm will
activate. To Set the HI Alarm:

1. Press the SET HI ALARM Function button once.

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4 Operation Model 3190

2. Within 5 seconds, press either the ∆ or ∇ button to raise or lower

the displayed value, as required, until the display reads the
desired concentration.

4.4.2 LO Alarm

Setting the LO Alarm sets the value BELOW which the LO alarm will

activate. To set the LO Alarm:

1. Press the SET LO ALARM Function button once.

2. Within 5 seconds, press either the ∆ or ∇ button to raise or lower

the displayed value, as required, until the display reads the
desired concentration.

4.4.3 Sensor Fail Alarm

The SENSOR FAIL alarm triggers if, during calibration, the raw cell
output for the given oxygen level is too low. (See Calibration
Characteristics in Chapter 2.) Should this alarm trigger, The ALARM
indicator below the SET function buttons will start blinking. Replace the cell
before proceeding.

4.5 Selecting a Fixed Range or Autoranging

The Model 3190 can operate in fixed high, fixed low, or autoranging
mode. To change modes:

1. Press and then release the SET HI RANGE and the SET LO
RANGE buttons simultaneously.

2. Within 5 seconds, press either the ∆ or ∇ button until Auto, Lo,
or Hi displays on the LCD, as desired.

After about three seconds, the analyzer resumes monitoring in the

selected range mode.

NOTE:If the concentration exceeds 9,999 ppm oxygen, the analyzer

will automatically switch to the Calibration Range, EVEN
THOUGH INSTRUMENT IS IN THE FIXED RANGE MODE.

4-4

4.6 Calibration

Preliminary—If not already done: Power up the Analyzer and

allow the LED reading to stabilize. Set the Alarm setpoints and
the fullscale ranges to the desired values.

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Trace Oxygen Analyzer Operation 4

Procedure:

1. Expose the sensor to ambient air or instrument grade air (20.9 %
oxygen). Allow time for the sampling system to purge and the
analyzer to achieve equilibrium.

Note: If the analyzer output goes above the high alarm setpoint or

below the low alarm setpoint, the front panel ALARM Indica­tor, beneath the SET Function buttons, will blink. When the
SPAN key is pressed to enter SPAN mode, Alarm indicator
stops blinking.

2. Press the SPAN button once.

3. Within 5 seconds press either the ∆ or ∇ button until the display
is stable and reads 20.9 %.

The unit is now calibrated.

Note: If you use a span gas other than air, do not span in the

0-10 ppm range. Calibration at this level is not dependable.

Note: If you use a span gas other than air, and the span gas oxygen

concentration is less than 10,000 ppm, the analyzer could take
up to 65 seconds to to settle. The lag is caused by a digital
filter that is active only below 10,000 ppm (1%) oxygen.

If the output of the sensor as measured by the 3190 outside of the

expected range due either to:

a) Bad electrical connection between the unit and the sensor,

b) Improperly analyzed or entered calibration gas value,

c) Electronics failure

The unit will not accept the calibration attemped and flash 5000 on the

LED display unit a valid calibration has been performed.

4.7 Displaying Percent & PPM on the LED

Display

The analyzer displays the concentration in percent whenever the read­ing is over 9999 ppm. When the reading changes to percent, the LED
display will alternate between flashing “PC” and the oxygen concentration.
On the other hand, if the instrument is displaying ppm, only the concentra­tion reading will be shown.

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4 Operation Model 3190

4.8 “SetL” mode in the LED display

When you turn on the unit, it displays “8.8.8.8” for a couple of seconds. This
is to have an inspection that all segments of the display are all right. After the
first two seconds, the LED display will show “SetL” and alternate with a
countdown starting at 34.0. This countdown is to let the electronics settle and
do a zero calibration of the electronics. Flowing “zero” gas or a sensor is not
needed for this instrument adjustment. It is only an electronic zero
calibration. The sensor is automatically disconnected by the 3190 hardware
during this mode. As soon as the countdown reaches 0.00, the analyzer will
go back to the normal mode of operation and the sensor is reconnected.

When the concentration rises above a point between 2000 to 3000 ppm
(it changes from sensor to sensor) there are a few seconds where the display
freezes. This is due to an automatic gain change to low gain. When the
concentration drops and crosses a point between 3000 and 1500 ppm (it
changes from sensor to sensor) the display will show “SetL” and alternate
with a countdown of 30 seconds. This is due to an automatic gain change to
high gain. It takes longer for the electronics to settle when switching to the
high gain than when switching to low gain, that is the reason why the count­down only appears when the sensor reading is going down and not up.

4-6

Teledyne Analytical Instruments

Trace Oxygen Analyzer Maintenance 5

Maintenance

Overvoltage
Category II

Aside from normal cleaning and checking for leaks, the Model 3190
should not require any maintenance beyond replacement of expended Micro­Fuel Cells, and perhaps a blown fuse. Routine maintenance includes occa­sional recalibration, as described in chapter 4, Operation.

5.1 Replacing the Fuse

5.1.1 AC Powered Units

When a fuse blows, check first to determine the cause, then replace the
fuse using the following procedure:

1. Disconnect the AC power and place the power switch located on

the rear panel in the O position. Remove the power cord from the
receptacle.

2. The fuse receptacle is located in the power cord receptacle
assembly in the upper left-hand corner of the rear panel. See
Figure 5-1.

Figure 5-1: AC Fuse Replacement

3. Insert a small flat-blade screwdriver into the slot in the receptacle
wall nearest the fuse and gently pry open the fuse receptacle. The
fuse holder will slide out. The fuse in use is visible in the clip. To

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5-1

5 Maintenance Model 3190

open the spare fuse compartment, push on one end until it slides
out.

4. Remove the blown fuse and replace it with a 5×20 mm 0.5 A,

250 VAC, IEC time lag (T) fuse (P/N F1128) for AC units.

5. Replace the fuse holder into its receptacle, pushing in firmly until
it clicks.

5.1.2 DC Powered Units

In units with DC power, the fuse is located on the rear panel above the

ON/OFF switch.

1. Open the fuse holder by unscrewing and removing the cap
marked FUSE.

2. The fuse is located inside the receptacle, not inside the cap. Both
terminals are on the same end of the fuse. Pull straight out
without twisting to remove the old fuse from the receptacle, and
replace it with a 0.5 A, 125 V dc, very quick acting (FF)
microfuse (P/N F51).

3. Replace the cap by screwing it back into the receptacle.

5.2 Sensor Installation or Replacement

5.2.1 When to Replace a Sensor

There are several symptoms that may indicate sensor weakness other

than the Sensor Failure Alarm.

• Cell failure in the 3190 is usually characterized very slow
response to changes in oxygen levels below 100 ppm. This can
cause errors in span calibration, since the sensor may not have
time to settle properly.

• If large adjustments are required to calibrate the instrument, or
calibration cannot be achieved within the range of the ∆∇
buttons, the cell may need replacing.

5-2

• If the front panel Trace Oxygen Meter displays “00.0” when the
unit is plugged in, and the power switch is in the ON position,
CHECK to make sure the sensor is connected. If it is, replace the
sensor.

Teledyne Analytical Instruments

Trace Oxygen Analyzer Maintenance 5

CAUTION: Read the section

Cell Warranty Conditions

, below,

before replacing the cell.

CAUTION: After replacing the Micro-Fuel Cell, the analyzer

must be recalibrated. See

5.2.2 Ordering and Handling of Spare Sensors

To have a replacement cell available when it is needed, TAI recom­mends that one spare cell be purchased when the current cell 's warranty
period is approximately two thirds over.

Calibration

in chapter 4.

CAUTION: Do not stockpile cells. The warranty period starts

on the day of shipment. For best results, do not
order a new spare cell to soon.

The spare cell should be carefully stored in an area that is not subject to
large variations in ambient temperature (75 °F nominal), and in such a way
as to eliminate the possibility of incurring damage.

CAUTION: Do not disturb the integrity of the cell package until

the cell is to actually be used. If the cell package is
punctured and air is permitted to enter, cell-life will
be compromised.

WARNING: THE SENSOR USED IN THE MODEL 3190 CON-

TAINS AN ELECTROLYTE WHICH INCLUDES
SUBSTANCES THAT ARE EXTREMELY HARMFUL
IF TOUCHED, SWALLOWED, OR INHALED. AVOID
CONTACT WITH ANY FLUID OR POWDER IN OR
AROUND THE UNIT. WHAT MAY APPEAR TO BE
PLAIN WATER COULD CONTAIN ONE OF THESE
TOXIC SUBSTANCES. IN CASE OF EYE CONTACT,
IMMEDIATELY FLUSH EYES WITH WATER FOR AT
LEAST 15 MINUTES. CALL A PHYSICIAN. (SEE
APPENDIX,

5.2.3 Removing the Micro-Fuel Cell

Refer to Figure 5-2 for an exploded view of the cell block and cell. To
remove a spent or damaged Micro-Fuel Cell:

1. Disconnect the Power Source at the Control Unit.

2. Disconnect the connector from the cell block if possible.

Material Safety Data Sheet

—MSDS).

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5 Maintenance Model 3190

3. Unscrew the cell-retainer cap from the cell block by turning it
counterclockwise until it is free.

Figure 5-2: Exploded View of MFC and Cell Block

4. Slowly withdraw the cap from the block. The cell should come
out with the cap.

5. Carefully pull the cell off of the cap. DO NOT TOUCH THE
SCREENED END OF THE CELL OR ANY FLUID THAT
MAY BE LEAKING FROM IT.

6. Dispose of the cell in a safe manner, in accordance with all

applicable ENVIRONMENTAL AND SAFETY laws.

5.2.4 Installing a Micro-Fuel Cell

To install a new Micro-Fuel Cell:

CAUTION: Do not scratch, puncture, or otherwise damage the

sensing membrane of the Micro-Fuel Cell. If the
membrane is damaged, the cell must be replaced.

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Trace Oxygen Analyzer Maintenance 5

1. Disconnect the Power Source from the Control Unit.

2. Remove the new Micro-Fuel Cell from its protective bag.

3. Examine the O-ring at the base of the threaded portion of the cell­retainer cap, and replace it if it is worn of damaged.

3. Replace the cell on the end of cell-retainer cap, which is designed
to fit snugly into the rim on the screen side of the cell.

4. Careful insert the cap and cell into the block, and screw the cap
clockwise into the cell block until it is held firmly in the cell.

5. Reconnect the cell block electrical connector plug.

5.2.5 Cell Warranty Conditions

The Class A-2C, B-2C or Z-2C Micro-Fuel cell is used in the Model

3190. These cells are warranted for 6 months, with an expected life of 8
months from the date of shipment (under specified operating conditions—see
Appendix). Note any Addenda attached to the front of this manual for
special information applying to your instrument.

Note that the warranty period begins on the date of shipment. The
customer should stock only one spare cell per instrument at a time. Do not
attempt to stockpile spare cells.

If a cell was working satisfactorily, but ceases to function before the
warranty period expires, the customer will receive credit toward the purchase
of a new cell.

If you have a warranty claim, you must return the cell in question to the
factory for evaluation. If it is determined that failure is due to faulty work-

manship or material, the cell will be replaced at no cost to you.

Note: Evidence of damage due to tampering or mishandling will

render the cell warranty null and void.

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5 Maintenance Model 3190

5-6

Teledyne Analytical Instruments

Trace Oxygen Analyzer Appendix

Appendix

A.1 Specifications

Overvoltage
Category II

Ranges: Two user selectable ranges can be set

between 0-10 ppm and 0-9,999 ppm
oxygen. Default ranges are 0-100 ppm and
0-1,000 ppm oxygen, and a 0-25 % (nomi­nal) Air Calibration Range.

Signal Output: Voltage: 0–10 V dc, negative ground

Current: 4-20 mA, negative ground

Range ID: 0-10 V dc.

Display: Light emitting diode (LED) display.

Alarms: One high alarm relay, adjustable; one low

alarm relay, adjustable; one sensor failure
relay. (All are failsafe.)

System Operating Temp: 0-50 °C

Accuracy: ±2 % of full scale at constant temperature

±5 % of full scale through operating tem­perature range (At 100 ppm and higher user
defined ranges) once temperature equilib­rium is reached.
±1 ppm for 10 ppm range under above
conditions.

Response Time: 90 % in less than 65 seconds at 25 °C

(68 °F).

System Power Requirement: AC (100 to 240 V ac, 47/440 Hz), or

DC (10-36 V dc); user specified.

System Enclosure: Panel Mount: 2.81" H × 6.0" W ×2.87" D

(71.4 mm × 152.4 mm ×72.9 mm).
Face Plate: 3.75" H ×7.0" W

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Appendix Model 3190

(95.3 mm H × 177.8 mm W). Face plate
rated to NEMA-4.

Sensor Type: Class A-2C, B-2C, and Z-2C

Analysis Unit: 4.0" H × 6.0" W × 2.5" D

(101.6 mm × 152.4 mm × 63.5 mm)

A.2 Spare Parts List

QTY P/N DESCRIPTION

1 C-65220-A PC Board, Main
1 C-64586 PC Board, Power Supply
1* C-6689-B-2C Micro-Fuel Cell, class B-2C
1* C-6689-Z-2C Micro-Fuel Cell, class Z-2C
2 F-1130 Fuse (AC), ½A, 250 VAC,

IEC Type T, 5 x 20mm
1 F-51 Fuse (DC), ½A, 125 VDC, Micro-Fuse
1 A-64678A Probe to Analyzer Cable, 6 ft
1* C-6689-A-2C Micro-Fuel Cell, class A-2C

* Order one type only: A-2C, B-2C, or Z-2C. See Specific Model Informa­tion in front of this manual for cell class supplied with your analyzer.

A minimum charge is applicable to spare parts orders.

IMPORTANT: Orders for replacement parts should include the part number

and the model and serial number of the system for which the
parts are intended.

Send orders to:

Teledyne Analytical Instruments

16830 Chestnut Street
City of Industry, CA 91749-1580

Telephone: [phone]
Web Site: www.teledyne-ai.com
Fax: [phone]

Technical Support: [phone]

Web: www.teledyne-ai.com

or your local representative.

A-2

Teledyne Analytical Instruments

Trace Oxygen Analyzer Appendix

A.3 Drawing List

C-64772 Outline diagram
C-64641 Final Assembly (and interconnection diagram)
D-65666 Control Unit Assembly
B-65992 Analysis unit outline

A.4 Miscellaneous

The symbol: ~ is used on the rear panel of the model 3190 to signify

volts alternating current (V ac).

NOTE: The MSDS on this material is available upon request

through the Teledyne Environmental, Health and
Safety Coordinator. Contact at [phone]

Teledyne Analytical Instruments

A-3

Appendix Model 3190

A-4

Teledyne Analytical Instruments